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*Lexmark T-630 Toner CartridgesDOC-0324

OVERVIEW

First introduced in June 2001, the Lexmark T630 series is based on the Lexmark T630 1200 dpi engine. Depending on themodel, the print speed is from 30-45 pages per minute. As with all of Lexmark’s new heavy duty machines these machines areloosely based on the older Optra S machines but these are much faster. Due to the speed and fuser characteristics, the toner iscompletely different. This toner is also different from the T620 series.

The machines currently available based on the T630 engine are:

T630 T630dn T630n

T630 T632dtnT632dtnf

T632n T634 T634dtnT634dtnfT634n T634tn

As with the T520/T620 machines, these cartridges have ARD (Anti-Recycling devices) installed in the Prebate or “ReturnProgram” cartridges that will not allow the cartridge to be used again until the chip board is replaced. As with other Lexmarkcartridges, the Non-prebate or standard cartridges will work with out replacing the chips. Lexmark seems to have abandonedthe Prebate name and gone with “Return Program” instead. Same mess, different name! The programming used in these chipsis similar to the code used in the new T420 series. Lexmark has added a few new wrinkles to the code that is making it a littleharder to develop a repair chip. It is currently being worked on and at the time of this writing (May,2003), chips are notavailable. They should be available as you read this. Check with your chip vendor to see if they are available.

The Encoder wheel in these cartridges does not indicate the toner yield as in the Optra S cartridges, that is now done by thechip. The encoder wheel only indicates if the cartridge is a Prebate or not.

For cartridges used in MICR only machines, make sure that the chip you are using is a dedicated MICR chip. This is alsostrictly a chip function. If the cartridge is to be used in other than a Lexmark machine the chip is different again. So far IBM,Dell, and Toshiba have not released any machines using this engine, but they probably will. As the chip will again be different,check with your chip supplier to make sure that their chip will work with your machine.

All that being said, these cartridges have a huge profit potential (See below). Even with the extra cost of the chip, and having tobe careful what machine it goes into, they are more than worthwhile to do.

The Lexmark Part #'s for these cartridges are as follows:

“Return Program” 5K*cartridge: 12A7460 list $99.00**

“Return Program” 21K*cartridge: 12A7462, List $330.00**“Return Program” 32K*cartridge: 12A7465, List $355.00**Standard 5K* cartridge:12A7360 list $149.00**Standard 21K* cartridge:12A7362, List $380.00**Standard 32K* cartridge:12A7365, List $405.00**

* Yield based on 5% coverage** List prices current as of May 27th 2003

There are also two label cartridges, the 12A7468, and the 12A7469.

Lexmark only lists the extra high yield cartridges (32K) for the T632 and the T634 series. The lower yield cartridges will give anunsupported cartridge error. The same will happen if the extra high yield cartridge is installed in the T630 machines.

The T63x series of cartridges are different physically from the T620 in that they have two large notches in the front edge of thewaste chamber. Since all of the cartridges from the Optra S on are somewhat similar, we are showing all the different cartridgeversions here. See Figure’s 1-6

FIGURE 1 FIGURE 2

FIGURE 3 FIGURE 4

FIGURE 5 FIGURE 6

As with the Optra S machines, the Primary Charge Roller (PCR) is not in the cartridge, it's in the printer, and is rated for300,000 pages. The Wiper Blade inside the cartridge has an external felt brush that keeps the PCR clean. Some of the startercartridges have wiper blades without this felt. It is very important that the blade be replaced with a new one that has the felt.Otherwise a buildup on the PCR may occur.

It should also be noted that because of the play between the toner hopper and the OPC drum, a shipping lock should beinstalled in every cartridge. This holds true even if you are going to hand deliver the cartridge. This holds true for all thecartridges based on the Optra S design.

Machine Cartridge/troubleshooting as well as how to run test prints will be covered at the end of this article.

REQUIRED TOOLS

Toner approved vacuum.

Small screwdriver (Common Style)

Phillips head screwdriver (#1)

Needle-nose pliers

Spring Hook

MATERIALS NEEDED

T-630 Toner: Use 188g for the 5K cartridge, 780g for the 21K cartridge, and 1200g for the 32K cartridge

Drum padding powder (Kynar) Do NOT use Zinc Sterate on these cartridges!

Cotton Swabs

Isopropyl Alcohol

Cotton Pads

Long life OPC Drum (Optional)(4059 Style)

Wiper Blade (4059 Style with PCR cleaner!)

Shipping Lock

Felt Wand (4059 Style)

Recovery Blade (4059 Style)

Retaining Blades

DISASSEMBLY

1. Vacuum the exterior of the toner cartridge. Be careful of the drum!

2. Place the cartridge on the bench drum side up (Label face down), with the toner supply towards you.

3. With a spring hook, remove the two springs from each end of the cartridge. See Figure 7

4. There are two plastic posts from the hopper that fit into the cartridge shell. Pull the edge of the shell out to release theposts, and lift up the hopper so that the posts are free. See Figure 8

5. Slide the hopper to the right, and remove from the cartridge. Pull it out so that the large white bearing comes free.Place the hopper aside. See Figure 9

6. Remove E-Ring from the small white helical gear end of the drum axle. There is no need to remove the opposite E-ring.See Figure 10

FIGURE 7 FIGURE 8

FIGURE 9 FIGURE 10

7. Slide the Drum Axle out of the cartridge. Hold the small helical gear while pulling it out so that the drum is not damagedin the process. Note the location of the small spring. See Figure’s 11 & 12

8. Gently lift the Drum up and out of the cartridge, if you are going to reuse the drum, place it in a light protected area. Becareful not to lose the spring, its’ purpose is to keep the drum from rotating backwards. See Figure 13

9. Remove the Wiper Blade by removing the two screws on either end of the Wiper Blade. See Figure 14

FIGURE 11 FIGURE 12

FIGURE 13 FIGURE 14

10. Place the cartridge so that the waste bin is face-up. Take a razor blade and cut the foam seal that runs along the backedge of the wiper blade to separate it from the cartridge. Make sure to cut along the plastic/foam, and not the blade.See Figure 15

11. Hold the cartridge so that it is up-right (Standing up with the waste bin on the table). With one hand, hold the lasershutter open, and with the other hand, remove the Wiper Blade. See Figure 16

NOTE1: The OEM Wiper Blade has the PCR cleaning assembly attached to it. It cannot be removed from the Bladewithout damaging it. Our new replacement Wiper Blades come complete with this assembly attached. The "Startercartridges" that came with a new printer do not have the PCR Cleaning Assembly on the Wiper Blade. The blades onthe starter cartridges must be replaced.

12. Make sure that the two end foams are clean and in their proper place See Figure 17

13. Pad the new Wiper Blade with Kynar padding powder, replace the blade and two screws into the cartridge. (Don’t useZinc Sterate on these cartridges! See Figure 18

FIGURE 15 FIGURE 16

FIGURE 17 FIGURE 18

14. Place a piece of clear tape along the edge of the Wiper Blade. If the tape does not stick well, the area should becleaned with alcohol. It is very important to get a good seal with the tape, otherwise the cartridge will leak. Trim awayany excess tape. See Figure 19

15. Be careful not to allow any tape into the laser port opening!

16. With a pair of needle nose pliers, gently pry off the Encoder Wheel. Make sure you pry it off from the center shaft sothat the wheel does not become damaged. Place the wheel in a safe place. Remember, this wheel tells the cartridgewhat type of cartridge it is, Prebate or Non-Prebate. The chip is what tells the machine what type of yield the cartridgehas. If this wheel becomes damaged, it must be replaced. See Figure 20

17. Remove the drive gear from the developer roller shaft. See Figure 21

18. Remove the Doctor Blade Spring by pressing down on the center of the spring. See Figure 22

FIGURE 19 FIGURE 20

FIGURE 21 FIGURE 22

19. Remove the metal contact plate from under the developer roller shaft and bushing. See Figure 23

20. On the left (fill Plug) side of the Static Roller there is a small metal bushing, take a small screwdriver, and pry thebushing up so that the tab on the bushing is facing up. This will release the bushing, and Developer Roller. See Figure24

21. Remove the Developer Roller. Note that the spacers are now clear instead of white. See Figures’ 25 & 26

FIGURE 23 FIGURE 24

FIGURE 25 FIGURE 26

NOTE: Always remove the Doctor Blade Spring before removing the Developer Roller, failure to do this will cause the DoctorBlade to slide down from its original position and break the seal.

22. Remove the fill plug from the hopper. Pry the plug out from the base next to the hopper. The fill plug is also a breathercap. It is best to remove both sections at once and to clean them from the outside. These plugs tend to leak if theyhave been separated. See Figure 27

23. Vacuum the Toner Hopper clean.

24. With a cotton swab dipped in alcohol, clean the Developer Roller seals located on either end of the static roller section.These seals are made of a white plastic. Also clean the electrical contact that touches the Developer Roller shaft. SeeFigure 28

25. Carefully vacuum or blow off the Developer Roller, Be careful not to touch the roller with your hands, or to damage thisroller in any way.

26. Inspect the inner and outer retaining blades (Black Mylar). If they are bent in any way, they must be replaced as theywill leak. See Figure 29

27. Install the contact plate onto the cartridge. See Figure 30

FIGURE 27 FIGURE 28

FIGURE 29 FIGURE 30

28. Place the keyed end of the Static Roller into the cartridge, and install the roller. See Figure 31

29. Install the bushing onto the developer roller shaft, turning it so that the tab is facing down. This will lock the roller inplace. See Figure 32

30. Install the Doctor Blade Spring. See Figure 33

31. Fill the hopper with the appropriate amount of toner. Remember, the amount of toner that can be placed in the cartridgeis controlled by the chip. Use 870G for the 30k cartridge, and 290g for the 10k cartridge. Install the Fill Plug. See Figure34

32. Install the Encoder Wheel

FIGURE 31 FIGURE 32

FIGURE 33 FIGURE 34

33. Take the OPC drum and lightly coat with the Drum Padding Powder,(Kynar). Do NOT use DPP (Zinc Sterate), thispowder will ruin the wiper blade.

34. Place the OPC Drum into the cartridge with the small helical gear on the NON-Contact side of the cartridge. Make surethat the spring is in the proper position! See Figure 35

35. Install the Drum Axle pin into the small white gear side of the drum.

36. The Axle must be installed this way to prevent the axle from bending and damaging the drum ground contact locatedinside the drum. See Figure 36

37. Install the E-Ring on the end of the axle. See Figure 37

38. Remove the old chip with a pair of pliers, and install the new chip. The chip will just pull out, and slide back in. Thereare a few different physical versions of the aftermarket chips. Check with your supplier for the correct instillation. SeeFigure 38

FIGURE 35 FIGURE 36

FIGURE 37 FIGURE 38

39. Take the Toner Hopper and install it left side first. Make sure that the left side post, and the white bearing are in theirproper slot. See Figure 39

40. On the right side of the cartridge, pull the cartridge shell out so that the right side post falls into its slot. See Figure 40

41. With the spring hook, replace both springs on to the Toner Supply Chamber. See Figure 41

42. Re-install the Developer Roller drive gear. See Figure 42

43. A shipping lock must now be installed. This lock should be used even if youare goingto hand deliver thecartridge. Itwill prevent the toner hopper from coming in contact with the OPC Drum, and causing damage to either the Drum orthe Developer Roller. Press the two red tabs into the sides of the cartridge as indicated in the picture supplied with thelock. See Figure 43

44. Although the only cartridges that come with the felt wands are the label type, we still feel that they should be included,and changed each cartridge. After running life tests on OEM cartridges in new machines, we have seen some dirtylooking upper fuser rollers.

45. Replace the felt wand in the machine by lifting up the external plastic cover located over the fuser assembly. This is thesame place that all the Optra S based machines use.

FIGURE 39 FIGURE 40

FIGURE 41 FIGURE 42

FIGURE 43

CARTRIDGE TROUBLESHOOTING

Dirty Primary Charge roller: Located inside the PRINTER, this will show on the test page as vertical gray streaks down thepage, or as a gray background throughout the page.

Scratched drum: this is shown by a very thin, perfectly straight line that runs from the top to the bottom of the test page.

Chipped drum: This will show as a dot or series of dots that repeat 2 times per page. Any drum defects will repeat 3 times perpage based on the drum circumference of 5.2".

Light damaged drum: This will show up as a shaded area on the test print that should be white. Again this will repeat 3 timesper page.

Bad wiper blade: This will show as either a gray line approximately 1/8" thick, or as shading across the entire page. In eithercase there will be a film of toner on the drum surface.

Weak Dr. Blade Spring: This will usually show as shaded areas on one or both sides of the page.

Machine Error Codes:

32

Unsupported Print cartridge: (Wrong chip, encoder wheel combination, orbad chip). If this happens immediately upon cartridge instillation, there iseither a bad contact to the chip, or the chip is bad. If the machine cyclesand then the message appears, the wrong encoder wheel is installed. Inthe T632 machines, this message will also show if the extra high yieldcartridge is not installed.

80 Scheduled maintenance (300,000 page)

88 Toner Low

200-280 Various paper jams

RUNNING TEST PAGES

Printer menu:

Press the “MENU” key until “Utilities Menu” is displayedPress “SELECT”Press the “MENU” key until “Print Menu” is displayedPress “SELECT” w:

Font Sample:

Press the “MENU” key until “Utilities Menu” is displayedPress “SELECT”Press the “MENU” key until “Print Fonts” is displayedPress “SELECT”Select either the PCL fonts or the Postscript fonts,Press “SELECT”

The Print Menu page contains the printer page count, toner level, cartridge serial number, cartridge size, if it is Prebate or not,and the cartridge type, (Normal, MICR, Label).

CHANGING THE PRINTER DENSITY

Press the “MENU” key until “Quality Menu” is displayed

Press “SELECT”

Press the “MENU” key until “Toner darkness” is displayed

Press “SELECT”

Choose a number between 1 and 10. “8” is the default setting

CHANGING THE PRINTER RESOLUTION

Press the “MENU” key until “Quality Menu” is displayed

Press “SELECT”

Press the “MENU” key until “Print Resolution” is displayed

Press “SELECT”

The options available are 300, 600, 1200 Image Q, and 1200 Dpi. The 1200 Image Q is for bitmapped pictures. The printer defaultis 600 Dpi.

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* These chips are designed to work on Non-Prebate, (Non-return) cartridges only